22012

Navigate to Diagnostics > Parameter > Spindle on the operator panel. Select the leading spindle channel and verify MD 3100 bit 0 setting. If set to 1, simulation is active.

Cross-check the following spindle MD 3100 bit 0 value. Confirm both spindles have matching simulation mode settings (both 0 for real operation, or both 1 for simulation).

Do not enable simulation mode on spindles intended for production synchronization; this blocks coupling.

If coupling is required, disable simulation mode on the leading spindle by setting MD 3100 bit 0 = 0, then reload the spindle parameter set via Startup > Reset NCK > Parameter Transfer.

Verify encoder feedback connectivity on the leading spindle (MD 3200 Spindle feedback type must match actual hardware: 0=no feedback, 1=encoder, 2=resolver). Confirm MD 3200 is not set to 0 if real synchronism is required.

Check the NCK cycle counter (Diagnostics > System Info > Cycle Counter). If a recent parameter modification occurred, confirm MD transfer completed without errors via Startup > Parameter Transfer status log.

In the PLC program, verify the spindle state before issuing COUPLE_SPINDLE. Add a state check that confirms both spindles have completed their initialization state (spind_state = READY) before coupling is attempted.

Execute a full Startup > Reset NCK (warm reset) followed by Startup > Parameter Transfer to force re-initialization of both spindle parameter sets and clear any stale simulation mode flags.

Warm reset will clear active program; save work first.

Retry the coupling command. If alarm 22012 persists, advance to the third cause block (parameter inheritance check).

Navigate to Diagnostics > Parameter > Channel. Verify MD 11000 for each channel: confirm the leading spindle is assigned to a dedicated spindle number (e.g., spindle 1) and the following spindle to a different spindle number (e.g., spindle 2). Do not share spindle assignments.

Check MD 20110 (Axis simulation on/off) for all axes in the leading spindle's channel. Ensure no axis mapped to the leading spindle has bit 0 = 1. If set, the channel-level simulation flag overrides spindle mode.

Verify MD 3100 is not linked to a common parameter set via macro parameter references. Review the spindle parameter structure in Diagnostics > Parameter > Spindle to confirm each spindle has independent MD 3100 settings with no cross-references.

If parameter conflicts are found, correct the MD values, re-upload via Startup > Parameter Transfer, and verify with Diagnostics > Parameter dump that both spindles show independent simulation mode states before retrying coupling.